Mastering Common Challenges in Pump Skid Design and Installation

Q&A with Jack Osborne, Graduate Technical Design Engineer

Designing and installing pump skids in industrial cooling systems requires precision and expertise. These systems are essential for efficient fluid transfer and pressure management, but they often present challenges, from space constraints to seamless integration with existing infrastructure.

We spoke with Jack Osborne, Graduate Technical Design Engineer at Summit Process Cooling, who has been at the forefront of designing innovative, customisable pump skids. He shares insights on how Summit is leading the way in overcoming common challenges through advanced engineering solutions tailored to customer needs.

1. What are the most common challenges you encounter when designing and installing pump skids?

One of the biggest challenges is space constraints. Many industrial facilities have limited room, making it difficult to fit pump skids into the available footprint. Poorly designed layouts can lead to higher installation costs and maintenance difficulties.

Another key challenge is integrating new skids with older systems, especially when dealing with non-standard configurations, different fitting types, and existing pipework. Ensuring operational efficiency is also crucial, as pump skids must be optimised for energy use, flow rates, and pressure requirements. Finally, meeting industry standards while maintaining ease of access for maintenance is essential.

2. How does Summit Process Cooling address the issue of space constraints?

We specialise in designing bespoke, customisable pump skids to fit the exact footprint of each facility. Our engineering team works closely with clients to maximise efficiency without occupying unnecessary floor space.

We focus on every detail, knowing that even small changes can significantly improve system performance. By tailoring each skid to the unique requirements of the facility, we ensure a high-performance solution that doesn’t compromise operational flexibility.

3. Integrating new pump skids with older systems can be tricky. How does Summit ensure a smooth process?

Integration is one of the more complex aspects, especially when working with older equipment and existing pipework. We use advanced engineering tools such as SolidWorks to create detailed 3D models, ensuring seamless interfacing with existing infrastructure. This precision helps to minimise downtime and prevent unexpected issues during installation, avoiding costly modifications or additional components.

Our standard pump skid range covers pipe header sizes from 1–6” and offers both low- and high-pressure pump options, allowing us to accommodate a wide range of flow and pressure demands. The range includes single or dual pump skid configurations, with the option of inverter-controlled (fixed-speed or variable-speed) operations.

For clients requiring a fully bespoke solution, we offer customisations such as additional pumps, inverter frames, or modular add-ons. Flexibility is key, ensuring that our pump skids integrate effortlessly into both new and existing systems.

4. How do you ensure pump skids operate as efficiently as possible?

Design implementation is key. We focus on minimising pressure losses within the system, selecting the right components and optimising component positioning to enhance efficiency. We offer a range of configuration options to ensure each pump skid is tailored to specific operational requirements.

By matching the pump skid’s capabilities to the actual facility demands, we optimise flow rates while avoiding issues such as pump cavitation or excessive wear and tear. Our designs also support lagging options, ensuring temperature consistency while keeping operational costs low and performance high.

5. Maintenance accessibility is always a concern. How do you ensure pump skids are easy to maintain?

Maintenance accessibility is a top priority in our designs. We ensure that key components such as binder points, drains, pressure transducers, temperature sensors, valves, pumps, and strainers are easily accessible for routine maintenance and commissioning.

For instance, our dual pump skids operate in a run-standby configuration, meaning one pump can be isolated for maintenance while the other remains operational. This eliminates downtime and allows for continuous system operation.

Our modular design ensures that all components—big or small—can be accessed quickly and efficiently, reducing maintenance time and labour costs while keeping facilities running smoothly.

6. Adhering to industry standards is crucial. How does Summit ensure compliance?

We take compliance seriously. Our engineering team stays up to date with the latest industry standards and regulations, ensuring that every pump skid we design meets safety, reliability, and performance requirements.

Whether it’s general industry standards or sector-specific guidelines, we ensure our systems are built to the highest standards, giving customers peace of mind that their equipment is safe, reliable, and regulation-compliant.

How is Summit Process Cooling leading the way in overcoming these challenges?

At Summit, we offer a broad range of solutions to meet industry demands. Our standard pump skid range provides a cost-effective, easy-to-install solution covering a wide range of flow and pressure requirements. Optional extras include inverter control, flow switches, and reorientation of suction/discharge headers for improved adaptability.

For those requiring a fully customised system, we offer bespoke solutions, whether that means multi-pump skids, stacked configurations, or alternative fabrication techniques. We are also able to provide press-fit systems (≤2.5”) for added flexibility.

From addressing space constraints with tailored designs to ensuring seamless integration with existing systems, we optimise performance and simplify maintenance. Our use of advanced design tools ensures efficiency, and our commitment to compliance guarantees that all systems are safe and reliable.

By leveraging cutting-edge fabrication techniques, intelligent design solutions, and a deep understanding of industry needs, Summit Process Cooling delivers pump skids that provide long-term reliability, efficiency, and value.

📩 Get in touch today at hello@summitprocesscooling.co.uk to discuss your requirements and solutions with our team of cooling experts.

For more information on Mastering Common Challenges in Pump Skid Design and Installation talk to Summit Process Cooling